Carel humiSteam Basic UE003 User manual

humiSteamLite
commercial electrode steam humidifiers
Installation
Operation
User Manual
Read and save these instructions.

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Installation, Operating & Maintenance Manual
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IMPORTANT
BEFORE INSTALLING OR HANDLING THE HUMIDIFIER PLEASE CAREFULLY READ AND FOLLOW THE
INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ILLUSTRATED ON THE
LABELS ATTACHED TO THE MACHINE.
This humidifier produces non-pressurized steam by means of electrodes immersed in the water contained in
the cylinder-boiler (hereafter called the cylinder). The electrodes pass current through the water, which also
provides resistance, heating the water into steam, which is used to humidify environments or industrial
processes, using special distributors.
The quality of the water used affects the process of evaporation, so the humidifier may be supplied with
untreated water, as long as this is drinkable and not softened or demineralized; the evaporated water is
automatically replaced using a fill valve. This humidifier has been designed exclusively to directly humidify
rooms or ducts, using a distribution system. The installation, use and maintenance operations must be carried
out according to the instructions contained in this manual and on the labels applied internally and externally.
The conditions of the environment and the power supply voltage must comply with the specified
values.
All other uses and modifications made to the humidifier that are not authorized by the manufacturer are
considered incorrect.
Liability for injury or damage caused by the incorrect use of the humidifier lies exclusively with the
user.
Please note that the humidifier contains powered electrical devices and hot surfaces.
All service and/or maintenance operations must be performed by specialist and qualified personnel
who are aware of the necessary precautions and are capable of performing the operations correctly.
Disconnect the humidifier from the main power supply before accessing any internal parts.
The humidifier must be installed in accordance with the local standards in force.
The local safety standards in force must be applied in all cases.
The humidifier is made up of metallic and plastic parts. All parts must be disposed of according to the
local standards on waste disposal.
Certification: the quality and safety of CAREL products are assured by CAREL's ISO 9001 certified design
and production system, as well as listings from UL, cUL, CE, TUV, ETL and others.

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Installation, Operating & Maintenance Manual
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Table of Contents
Models And Description Of The Components .........................................................................6
How The Humisteam Works....................................................................................................7
1 Installation ............................................................................................................................8
1.1 Positioning .....................................................................................................................8
1.2.1 Removing the front cover ........................................................................................9
1.2.2 Fastening to the wall ...............................................................................................9
1.3 Plumbing......................................................................................................................10
1.3.1 Water supply .........................................................................................................10
1.3.2 Water drain............................................................................................................11
1.4 Steam distribution ........................................................................................................13
1.4.1 Duct injection.........................................................................................................13
1.4.3 Room distribution blower units ..............................................................................15
1.5 Power wiring ................................................................................................................16
1.6 Control wiring...............................................................................................................17
1.6.1 REHUMST Wall and Duct Humidistat ...................................................................19
1.6.2 PC-301 Air Proving Switch ....................................................................................20
2 Start-Up..............................................................................................................................21
2.1 Startup Checklist..........................................................................................................21
2.2 The HumiControl Controller .........................................................................................22
2.3 Start-up Procedure ......................................................................................................22
3 Operation ...........................................................................................................................22
3.1 Manual Drain ...............................................................................................................22
3.2 Seasonal Shut Down ...................................................................................................22
3.3 Alarms..........................................................................................................................23
3.4 Trouble-Shooting .........................................................................................................24
4 Maintenance.......................................................................................................................26
4.1 Periodic checks............................................................................................................26
4.2 Cylinder maintenance ..................................................................................................26
4.2.1 Replacing the cylinder ...........................................................................................26
Maintenance of the other plumbing components............................................................27
4.3 Replacement Parts ......................................................................................................28
4.3.1 Single Phase Humidifiers ......................................................................................28
5 Wiring Diagrams.................................................................................................................29
6 Technical Specifications.....................................................................................................30
IMPORTANT: BEFORE beginning installation:
•Check for shipping damage to cartons. Mark the shipping waybill accordingly
•Open cartons and check for any hidden damage. Mark the shipping waybill accordingly.
•Check packing slip to ensure all items have been received. Notify CAREL of any shortages or
damaged parts. You must notify CAREL USA within 5 working days of any shortages.
Copyright © 2005 by CAREL USA, LLC. All rights reserved.

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Models and Description of the Components
Model Selection
UE 003 P D 000 U 1 0
UE =
Electrode Capacity (KG) P Control Power supply
Version
number USA Cylinder Type Internal Use
003 = 7 lbs/hr On/off U = 208/1
005 = 11 lbs/hr D = 230/1
Internal
use only
1 = Disposable
Standard
Conductivity
2 = Disposable
Low
Conductivity
Example: UE003PD000U1 is a 7 lb/hr, 230/1 unit, and disposable standard conductivity cylinder
UE003, UE005
No. Description
1 Steam generator cylinder
2 Water drain valve
3 Power contactor
4 Fuses
5 Power transformer
6 Relay board
7 On/Off and Manual drain switch
8 Wiring terminal block
9 Water fill valve

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How the HumiSteam Works
HumiSteam is an electrode humidifier. It produces steam for humidification by passing electrode current
through the water in the steam generator cylinder between metal electrodes. There are no heater elements.
Steam output is directly proportional to the conductivity of the water, and the amount of electrode immersed in
the water.
On a call for humidity, the HumiSteam controller will open the water fill valve (1) and allow water to enter the
system. A flow restrictor (2) prevents the unit from filling too quickly or with too much pressure. The water
flows up the fill tube (3) and into the fill cup (7), where it flows over the conductivity probes (6), which feed the
water conductivity back to the controller for analysis. Water then flows over the dam in the fill cup (7), which
creates a 1” air gap to prevent backflow of contaminated water into the feed lines, and through the fill tube (4)
and into the bottom of the steam cylinder (11).
As the water fills the cylinder, it will reach the electrodes (10) and current will begin to flow. As the water
continues to fill the cylinder, the current will increase, and this is monitored by an amperage transformer placed
on one of the power wires (9). When the desired current is reached, the fill valve will close (1) and the water
will then begin to warm and produce steam. If the water reaches the cylinder full probes (8) prior to reaching
the desired current level, the fill valve (1) will be closed to prevent overflow. If the current rises too much as the
water fills the cylinder, the drain valve or pump (13) will be activated to drain away some water and reduce the
current flow.
Periodically, based on the incoming water conductivity, the unit will drain some water to reduce the mineral
concentration. A strainer (12) in the cylinder helps to prevent mineral debris from jamming the drain valve (13).
If there is no water in the cylinder, there will be no current flow and no steam production. The electrodes do not
burn out, but they will eventually become completely coated with mineral and the cylinder will then need to be
replaced or cleaned.

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1 Installation
1.1 Positioning
The HumiSteam has been designed for wall mounting
(although it can be placed on a stand) and, since it is an
atmospheric steam humidifier, should be placed close to
the point where the steam will be used, to minimize the
steam hose length (and condensate). Certain clearances
must be maintained around the unit:
A B C D E F
Minimum
Dimension
(inches)
12 8 8 16 28 < 0.5°
With room blower units, other clearances are needed:
Unit Dimensions:
A B C D E F H
Minimum
dimension
(inches) 20 72 72 24 20 72 24
UE003, UE005
Dimensions A 14.4
(inches) B 10.8
C 24.4
Weight packaged
35.3
(lbs) empty
30
installed 41.9

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1.2 Mounting
1.2.1 Removing the front cover
The front cover is secured by a capture screw located underneath the CAREL
logo. Twist the CAREL logo to reveal the screw, and use a phillips head
screwdriver to remove it. Then simply lift the front cover and pull out to remove
it. Return it in reverse order.
1.2.2 Fastening to the wall
Using the screws and anchors supplied, fasten the mounting bracket to the wall.
Be sure that the screws anchor firmly into studs or supports. Note the unit
installed weights from the Positioning section.
Once the mounting bracket is secured to the wall, hang the unit on the bracket. Fasten the remaining capture
screws through the bottom holes in the unit to secure it to the wall.
Dimension UE003, UE005
X 8.67
Y 19.69

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1.3 Plumbing
1.3.1 Water supply
The HumiSteam must be supplied with water (not softened)
having the following characteristics:
The water feed line should be ½” copper, PVC or poly tubing
run to within 3 feet of the humidifier, then bushed down to ¼”
O.D. copper or poly to make the final connection to the ¼”
O.D. compression fitting underneath the humidifier. With poly tubing an insert should be used to support the
tubing and prevent leaks. This insert is not provided.
SUPPLY WATER LIMIT VALUES FOR THE MEDIUM-LOW MEDIUM-HIGH
IMMERSED ELECTRODE HUMIDIFIERS CONDUCTIVITY CONDUCTIVITY
MINIMUM MAXIMUM MINIMUM MAXIMUM
Specific conductivity at 20°C σ20 µS/cm 125 550 300 1250
Total dissolved solids TDS mg/l 116 (1) 512 (1) 279 (1) 1163 (1)
Dry residue at 180°C R180 mg/l 81 (1) 358 (1) 195 (1) 813 (1)
Hydrogen ion activity pH 7 8.5 7 8.5
Total hardness TH mg/l CaCO350 (2) 250 100 (2) 400
Temporary hardness mg/l CaCO330 (3) 150 60 (3) 300
Chlorides ppm Cl = 20 = 30
Iron + Manganese mg/l Fe+Mn = 0.2 = 0.2
Silica mg/l SiO2= 20 = 20
Residual chlorine mg/l Cl-= 0.2 = 0.2
Calcium sulphate mg/l CaSO4= 60 = 100
Metal impurities mg/l 0 0 0 0
Solvents, thinners, detergents, lubricants mg/l 0 0 0 0
(1) Values depend on the specific conductivity; in general: TDS @0.93 * s20 ; R180 @0.65 * s20
(2) No less than 200% of the chloride content in mg/l Cl-
(3) No less than 300% of the chloride content in mg/l
NOTE: Softened water should NOT be used as it is generally corrossive to the electrode plating.
UE003, UE005
Instant flow rate 0.2 gpm
Connection 1/4" O.D. Compression
Temperature limits 34 to 104°F
Pressure limits 15 to 116 psi
Hardness limits <= 400 ppm CaCO3
Conductivity range 125 to 1250 µS/cm (micromhos)

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1.3.2 Water drain
The HumiSteam also requires connection to a drain. The drain water characteristics are:
The drain line can be 1-1/2” schedule 40 CPVC, 1-1/2” copper, or 1-1/2” Polypropylene. In all cases, the drain
tube is slipped over the drain outlet on the bottom of the humidifier. It is not glued or otherwise attached to the
humidifier, so it must be supported by itself.
Drain line must be installed and plumbed to an open drain immediately after the unit. For proper operation of
the unit, the open drain should be installed before the trap (if allowed by local code).
WARNING: Do NOT use PVC piping unless the unit has the optional drain tempering valve installed.
UE003 UE005
Drain rate per hour 2.2 gph 3.7 gph
Instant drain rate 1.3 gpm
Connection 1-1/2" nominal diameter
Typical temperature 212°F

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Physical location of the supply and drain connections are located as shown below.
NOTE: Carel can provide a drain tempering system which limits the water drain to no more than 140°F.

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1.4 Steam distribution
1.4.1 Duct injection
If you are using stainless steel duct steam distributor pipes:
They must be mounted completely level in the duct with the steam outlet holes facing up as shown above.
Support the end of longer distributor pipes if needed. Generally the distributor pipes should be mounted in the
center of the air stream with a minimum of 6” from the center of the distributor pipe to the top of the duct and 3”
minimum to the bottom. In vertical ducts, the distributor pipes are mounted in the center with the holes facing
up. The airflow may be up or down, but when the airflow is down, maximum velocity is 1,500 fpm. Note: end
support bracket is only supplied with distributors of 36” and larger length.
To install the stainless steel distributor pipes:
1. Cut a key shaped hole in the side of the duct to match the steam pipe and condensate return as
shown at right.
2. Apply silicone sealant to the mounting plate and insert the pipe through the hole and secure it with 4
sheet metal screws.
3. Connect the steam and condensate hoses using the hose clamps supplied.
If you are using the duct kit, it includes the SDPOEM22 plastic steam distribution nozzle:
As with the stainless steel distributors, cut a hole in the duct to match the insertion part, apply silicon sealant to
the duct mounting plate, fasten with 4 sheet metal screws and connect the steam hose and condensate lines
using the hose clamps provided.
NOTE: The SDPOEM accommodates both the 22mm I.D. hose and the 30mm I.D. hose. If you are using the
30mm I.D. steam hose, you should cut off the smaller steam inlet at the cut line shown above.
IMPORTANT: Allow 2 feet of straight duct downstream of the distributor pipes when the air temperature
will be >55oF. Allow 3 feet of straight duct if the air temperature will be <50oF. Always allow 2 feet
upstream. Turbulent air flow may require longer lengths.

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1.4.2 Steam Hoses
NINETY PERCENT (90%) OF ALL OPERATION PROBLEMS ARE CREATED BY IMPROPER STEAM
PIPING FROM THE HUMIDIFIER UNIT TO THE DUCT DISTRIBUTOR PIPES. To avoid these problems,
remember one simple fact when running the steam hose: steam naturally flows up hill, and condensate
naturally flows down hill. Run the steam hose or piping to avoid any kinks, sharp elbows, or low spots that could
collect or restrict the flow of steam to the distributor pipe, or the flow of condensate back to the humidifier.
Support the hose adequately to avoid sags.
The following diagrams are to provide you with some guidelines. If you have a situation you are unsure of,
please contact the factory for instructions.
IMPORTANT: Maximum length of rubber steam hose is 20 feet. Insulated copper tubing may be up to 40
feet. In all cases, minimize sharp bends and elbows – use 2-45° elbows instead of 90°s.
Hose size for UE 001, 003 = 22 mm.
Hose size for UE 005 = 30 mm.

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1.4.3 Room distribution blower units
Refer to the manual supplied with the Room Distribution Units for specifics on the blower units themselves.
Clearances required are shown below.
A B C D E F H
Minimum
dimension
(inches) 20 72 72 24 20 72 24
UE003, UE005
Room Blower
Unit Model VSDU0A
Rated Power
Volts 24
Air Volume
CFM 112
Noise Level
dBA 30
Operating Temp/Humidity 14 to 104°F
(°F / %RH) / 10 to 60%

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1.5 Power wiring
Check that the power supply voltage to be connected matches the value indicated on the
rating plate inside the electrical panel. Insert the power and ground connection cables into
the electrical panel compartment using the strain reliefs supplied, and connect to the
terminals. An external fused disconnect must be installed.
All wiring must be in accordance with local, state and national electric codes.
NOTE: to avoid unwanted interference, the power cables should be kept separate from any
control wiring.
Make sure that the TAM on the circuit board has the proper number of power wire turns through it, and that the
TA Rate DIP switches on the control board are set per the table at the bottom of this page.
Nominal Turns
Voltage Voltage Current Power Output Output Through
Model Code Phase (Amps) (kW) (kg/hr) (lbs/hr) TAM TA Rate
U 208 - 1~N 10.8 2 60
UE003 D 230 - 1~N 9.8 2.25 3 6.6 1 20
U 208 - 1~N 18 1 40
UE005 D 230 - 1~N 16.3 3.75 5 11 1 40
NOTE: Tolerance allowed on main voltage = -15%, +10%

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1.6 Control wiring
The HumiSteam Lite control system allows one humidistat to be
connected, as well as various safety devices, remote on/off,
alarm and serial communications.
Generally, the control humidistat (H) is located in the room or
return air duct. In the case where the HumiSteam uses a direct
discharge blower unit, this is the only control needed. In ducts
or air handlers, a high limit humidistat is usually added to act as
a safety (CR), as well as an air flow proving device.
Control wiring is made directly to the control
board terminals:
1. alarm output terminal block;
2. control signal terminal block;
3. DIP switches for selecting drain mode;
4. DIP switches for selecting TA RATE.
Control Signal Terminal Block (# 2 in diagram)
NOTE: DO NOT apply any voltage to terminals AB & AB. Connect external dry contact or jumper wire
ONLY.
Terminal Function Electrical specifications
+VR output voltage for sensors 10V; min. 5 k-ohm
range: 0 to 10 V;
SET control signal input input impedance: 15 k-ohm
GND common for +VR and SET
Connects to external NO contact;
Maximum resistance = 50 ohm;
Maximum impedence = 10mAdc;
AB
AB remote enabling input
humidifier enabled = contact closed

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For On/Off Operation (diagram at right):
Connect any simple humidistat, high-limits, air flow switch,
and remote contacts in series from terminals AB to AB.
Circuits must be completed from +VR to SET by a jumper
and from AB to AB for the unit to operate. Use jumpers if
devices are not connected.
In the case where it is necessary to have the furnace fan
start when humidification is needed, a SPDT relay must
be added to power both the fan and the humidifier, per
the diagram at right.
Alarm Output:
The H terminals allows connection to an on-board SPDT alarm relay that provides
No and NC contacts for remote indication of alarms. The relay is rated for up to
250V, 5A max. resistive and 2A max. inductive.

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1.6.1 REHUMST Wall and Duct Humidistat
The REHUMST is designed to operate as a wall mount or duct mount humidistat. Figure 1 shows how to
assemble the unit for wall mounting. Figure 2 shows how to assemble the unit for duct mounting.
The REHUMST has only two wiring
connection terminals, which eliminates any
confusion.
Mount the REHUMST either on the wall in
the area to be humidified, or on the return
air duct.
The range of the instrument does not permit
its use as a high limit device.
Function RH Range Switch VAC FLA
Humidistat 10 to 60%RH SPST <30 Vac 7.5 Amps

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1.6.2 PC-301 Air Proving Switch
Mounting the PC-301 air flow switch:
Mount the airflow switch in the supply or return duct using the
screws supplied. Mount the device so that the diaphragm is in
a vertical position as shown at right.
If the airflow switch is to be mounted on the return duct
(vacuum), then mount it in a vertical position by the small
plate. Drill a 7/16" hole in the side of the duct and connect the
supplied tubing to the low pressure tap on the airflow switch
and then run it through the drilled hole in the duct. Put no more
than 2" of tubing into the duct. Caulk around the tubing where
it enters the duct. The high pressure tap is left open to
atmosphere.
If the airflow switch is to be mounted to the supply duct
(pressure), then simply drill a 7/16 hole in the side of the duct, apply caulking to the large plate, and mount the
device with the large plate to the duct and the high pressure tap/tubing mated the hole. The low pressure tap is
left open to atmosphere.
MOUNTING DIAGRAMS
TABLE 1. MAXIMUM ELECTRICAL SWITCH RATINGS
Vac Full Load
Amps Locked Rotor Amps Pilot Duty (VA) Non- Inductive
Amps
24V - - 60 10
120V 6.25 37.5 300 10
240V 3.1 18.6 300 10
277V 2.7 16.2 300 10
WIRING DIAGRAM
N.C.
C
ommon I ncrease
P
ressure
N.O. makes on increase N.O.
in pressure.